Wireless Control And Status Monitoring For Electric Grill With Current Protection Circuitry

ABSTRACT

Provided is an apparatus and method for protecting against unsafe electric current conditions. A protections circuit may be used in a device, such as an electric grill, that has one or more electric loads, such as heating elements. The protection circuit may protect against various failure scenarios, including, without limitation, instances of ground fault, over current, driver failure, and failure of a microprocessor. The microprocessor may further be in wireless communication with a remote device and wirelessly communicate error codes indicative of an error, and receive control signals from the remote device for controlling temperature or turning the grill off. The remote device may also receive operating parameters and create a log of the electric grill&#39;s conditions at the time of an error.

RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.15/200,687, filed on Jul. 1, 2016, and incorporated herein in itsentirety by reference.

FIELD OF THE INVENTION

The present inventions relate generally to electric grills and moreparticularly, to electric grills having advanced circuitry to protectagainst dangerous, faulty and unexpected current conditions. Theelectric grill may further includes a wireless controller for wirelesslycommunicating with a remote device in order to transfer operatingparameters and to wirelessly control and monitor the grill.

BACKGROUND OF THE INVENTION

There is an increasing desire for electric grills. This is particularlytrue because the urban population is expanding. Many urban or otherenvironments may not easily permit the use of traditional gas orcharcoal grills. For example, many urban dwellers live in apartments orcondominiums having balconies where they would like to use a grill.Because of smoke, gas or other concerns, use of typical charcoal or gasgrills may not be permitted or desirable.

There are a number of available electric cooking devices, such as theGeorge Foreman Plate Grill (and similar devices), panini presses,electric griddles and the like. However, these prior art electriccooking devices are typically intended for indoor use and are notdesigned or constructed for use in harsh or caustic environments wherethey may be degraded by high heat, weather conditions such as sun andrain, as well as fats from foods or acids from cleaning agents. Theseharsh conditions may cause the electrical components to degrade, whichin turn may lead to electrical current leakage or other unsafeconditions.

Because prior art electric cooking devices are generally intended forindoor environments, a typical wall outlet's current protection schemeis generally sufficient for these devices. Such devices may also rely ona ground line for protection. Some prior art circuits includemetal-oxide-semiconductor field-effect transistors (MOSFETs) to regulatecurrent. Yet other prior art circuits are thermally-responsive. However,there is a need for advanced protection circuitry in an electric grillthat can respond to the failure of components, including but not limitedto those which cause improper current conditions, such as those that maybe found in or caused by harsh environments.

For example, U.S. Pat. No. 8,263,911, entitled “Electronic Device withHeating Protection Circuit and Heating Protection Method Thereof,”discloses an electronic device in which a control signal generated by acontrol module can assist the heating protection circuit in correctlydetermining whether a heating signal is failed or whether a controlvoltage of a control element is abnormal, and then automatically controlthe heating module to stop heating. The heating protection circuit usesa MOSFET coupled with a control module and a heating switch module. Bycontrast, some embodiments of the present invention use a combination ofelectro-mechanical and digital logic to detect multiple different typesof failure conditions that simply cannot be detected by a MOSFET heatingprotection circuit.

Other prior art devices, referred to as thermally-responsive circuits,may shut down when a heating element reaches a threshold temperature.For example, U.S. Pat. No. 8,097,835, entitled “Temperature ControlCircuit,” discloses a temperature detecting module which detects thetemperature of the electronic device for outputting a detection signalto a protection module and microprocessors. The protection modulecontrols the status of the microprocessor. But such thermally responsivecircuits are inadequate for harsh environments and current conditionswhich may lead to component failures. In fact, failed components maylead to current leakage, which does not always correlate with anoverheated heating element. Dangerous current conditions may occur evenif a heating element is within normal temperatures.

Thus, there is a need for an electric grill, including a grill with oneor more independently controlled heating elements, having protectioncircuitry that protects against, among others things, short circuits,overcurrent, driver failure and/or microcontroller failure. Moreover,there is also a need for embodiments for an electric grill capable ofcommunicating wirelessly with a remote device, such as a cell phone ortablet, to control the electric grill and convey operational informationto a user. Such an electric grill can be monitored remotely by a user,where the user may be able to view operational information and controlthe grill remotely. For example, the electric grill may wirelesslyconvey operational parameters including include the cooking status ofthe electric grill, as well as an indication of whether the electricgrill is operating normally (and if not, indicating which type of errorhas occurred).

BRIEF SUMMARY OF THE INVENTIONS

The present inventions overcome many of the deficiencies of knownelectric cooking devices and provide new features and advantages forelectric grills. For example, the present inventions provide protectioncircuitry that shuts off power to the heating element or elements in thecase of faulty, unexpected and/or dangerous current conditions.Moreover, embodiments of the present inventions provide an electricgrill that is in wireless communication with a remote device andcommunicates various operational information, including the occurrenceof dangerous current conditions, to a user.

The present inventions generally provide an electric grill withcircuitry and a microprocessor configured to protect against unsafeelectric current conditions. For example, embodiments of the inventionsinclude a system for monitoring a status of an electric grill, thesystem having at least one heating element connectable to a voltage lineand a neutral line; a Hall Effect sensor configured to measure currentpassing to said at least one heating element, a ground fault detectionunit configured to detect a ground fault error between the voltage lineand the neutral line; a wireless controller; and a microprocessor, themicroprocessor being in communication with the Hall Effect sensor, theground fault detection unit, and the wireless controller; wherein themicroprocessor is adapted and configured to wirelessly send and receivesignals to and from a remote device via the wireless controller.

Moreover, the microprocessor may be adapted and configured to identifyan overcurrent error by comparing a current reading from the Hall Effectsensor to a predetermined current threshold, and to wirelessly send anerror code to the remote device in response to an overcurrent error. Themicroprocessor may be adapted and configured to identify a current errorby comparing a current reading from the Hall Effect sensor to anexpected current, and to wirelessly send an error code to the remotedevice in response to a current error. Further yet, the microprocessormay be adapted and configured to receive a signal indicative of a groundfault error from the ground fault detection unit, and is further adaptedand configured to wirelessly send an error code to the remote device inresponse to a ground fault error.

In some embodiments, the microprocessor is connected to a relay or atriac driver for controlling the current delivered to the at least oneheating element. In additional features, the microprocessor may beadapted and configured to wirelessly receive an “off” signal from theremote device and, in response, to disable current from being deliveredto the at least one heating element. Further yet, embodiments mayinclude a cook box and at least one temperature sensing device formeasuring a temperature inside the cook box, wherein the temperaturesensing device is in electronic communication with the microprocessor.The inventions may further comprise a display in electroniccommunication with the microprocessor, wherein the microprocessor isadapted and configured to display the temperature on the display. Themicroprocessor may be further adapted and configured to toggle betweendisplaying the temperature in Celsius or Fahrenheit in response to awireless signal from the remote device.

Furthermore, the microprocessor may be adapted and configured towirelessly transmit the temperature inside the cook box to the remotedevice. Moreover, the microprocessor may be adapted and configured torecord operating parameters of the electric grill and to wirelesslytransmit the operating parameters to the remote device. Themicroprocessor's transmission of operating parameters may be adapted andconfigured to be continuous, or the microprocessor's transmission ofoperating parameters can be adapted and configured to be in response toan error. The operating parameters may comprise a temperaturemeasurement. Further, the operating parameters may comprise a timerindicative of the amount of time the heating element has been active.The microprocessor may be a chip having a self-check pin, and thewireless controller may be adapter and configured to wirelessly send anerode code to the remote device in response to a self-check signalindicating a microprocessor error.

Additional embodiments provide a system for wirelessly monitoring anelectric grill's status, comprising an electric grill having protectioncircuitry, the protection circuitry comprising a microprocessor inelectronic communication with a ground fault detection unit and a HallEffect sensor; and a wireless controller in electronic communicationwith the microprocessor; wherein the microprocessor is configured toreceive electronic signals from the ground fault detection unit and theHall Effect sensor; and wherein the microprocessor is further adaptedand configured to determine the occurrence of an error and, in response,wirelessly communicate an error code. Further, a remote device may beadapted and configured for wireless communication with the wirelesscontroller, wherein the remote device is adapted and configured towirelessly receive an error code. Moreover, the remote device can beadapted and configured to display, on a display, a message indicative ofthe type of error corresponding to the received error code. The remotedevice may be a cell phone, tablet and/or a computer.

Also provided is a method for wirelessly monitoring an electric grill'sstatus, comprising the steps of: using a microprocessor in communicationwith a ground fault detection unit and a Hall Effect sensor to detect anerror in the electric grill's operation; transmitting, wirelessly, anerror code indicative of the error to a remote device. The method mayadditionally include the steps of: using the microprocessor tocommunicate with a temperature sensing device to measure the electricgrill's temperature; using the microprocessor to determine the electricgrill's active time; and transmitting, wirelessly, the electric grill'stemperature and active time to the remote device.

In additional embodiments, the method includes using the remote deviceto display, at the remote device, a message indicative of the errorreceived; and using the remote device to create and store a log in amemory, wherein the log comprises an error code, the electric grill'stemperature, and the electric grill's active time. The remote device maycommunicate the log over the internet. Disclosed methods further includethe step of using the remote device to communicate the log over theinternet; the step of displaying, on a display at the electric grill,the electric grill's temperature; and the step of using the remotedevice to wirelessly toggle the display between Celsius and Fahrenheit.

An object of the present inventions is to provide a protection circuitthat allows an electric grill to remain in an outdoor environment forprolonged periods of time without creating dangerous electric conditionsand/or which protects the components of the grill.

An additional object of the present inventions is to provide an electricgrill that can safely be used in outdoor or harsh environments.

A further object of the present inventions is to provide a protectioncircuit that detects current leakage and responds by disabling the flowof current.

A further object of the present inventions is to provide a protectioncircuit that detects a ground fault and responds by disabling the flowof current.

A further object of the present inventions is to provide a protectioncircuit that detects an unbalanced current and responds by disabling theflow of current.

Still another object of the present inventions is to provide aprotection circuit that detects an overcurrent and responds by disablingthe flow of current.

Still an additional object of the present inventions is to provide aprotection circuit that detects a current draw that differs from anexpected current draw and responds by disabling the flow of current.

Still yet a further object of the present inventions is to provide aprotection circuit that includes a microprocessor and can detect whenthe microprocessor enters an abnormal state of operation.

And yet another object of the present inventions is to disable currentflowing through an electric grill when an unsafe operating condition orfailure scenario is detected.

Further objects of the invention include wirelessly communicating anerror code indicative or an error to a remote device. Moreover, objectsof the invention include displaying an electric grill's operatingparameters at a remote device, and controlling the electric grill fromthe remote device.

And still yet another object of the present inventions is to provide aprotection circuit that may be used on an electric grill or otherdevices, for indoor and/or outdoor use, to protect against unwanted,unsafe and/or unexpected current conditions.

Inventors' Definition of Terms

The terms used in the claims of this patent are intended to have theirbroadest meaning consistent with the requirements of law. Wherealternative meanings are possible, the broadest meaning is intended. Allwords used in the claims are intended to be used in the normal,customary usage of grammar and the English language.

BRIEF DESCRIPTION OF THE DRAWINGS

The stated and unstated features, objects and advantages of the presentinvention (sometimes used in the singular, but not excluding the plural)will become apparent from the following description and drawings,wherein the like reference numerals represent like elements in thevarious views and in which:

FIG. 1A is a front view of an exemplary electric grill of the presentinvention.

FIG. 1B is a top schematic view through a typical cooking surface of arepresentative electric grill of the present invention showing internalcomponents.

FIG. 2 is a schematic of an embodiment of a protection circuit of thepresent invention.

FIG. 3 is an exemplary schematic showing an isolated view of one or moreheating elements driven by one or more triacs of the present invention.

FIG. 4 is an exemplary schematic showing an isolated view of a currenttransformer used to generate a trip control signal of the presentinvention.

FIG. 5 is an isolated diagram of a microprocessor and exemplary inputsand outputs that may connect to the microprocessor of the presentinvention.

FIG. 6 is a flow chart showing a microprocessor detecting an unexpectedcurrent or overcurrent condition of the present invention.

FIG. 7 is a schematic of an embodiment of a protection circuit of thepresent invention including a wireless controller.

FIG. 8A is a graph showing exemplary temperature fluctuations of anelectric grill operating in a medium temperature range.

FIG. 8B is a graph showing exemplary temperature fluctuations of anelectric grill operating in a low temperature range.

FIG. 8C is a graph showing exemplary temperature fluctuations of anelectric grill operating at a high temperature range.

FIG. 9 is an exemplary schematic of an electric grill in wirelesscommunication with a remote device.

FIG. 10 is an exemplary graph showing estimated ambient temperaturesinside a grill box based on measurements taken near a grill's heatingelements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Set forth below is a description of what is currently believed to be thepreferred embodiments or best representative examples of the inventionsclaimed. Future and present representative or modifications to theembodiments and preferred embodiments are contemplated. Any alterationsor modifications which make insubstantial changes in function, purpose,structure or result are intended to be covered by the claims of thispatent. The present inventions may be used on and/or part of electricgrills with a digital power supply as discussed in the co-pending patentapplication entitled “Digital Power Supply” filed by Applicants andhaving application Ser. No. 15/200,759, and also the co-pending patentapplication entitled “Digital Power Supply with Wireless Monitoring andControl,” filed on the same day as this application, both of which areassigned to Weber-Stephen Products LLC, and which are both incorporatedherein by reference in their entirety.

The use of electric heating elements 103, 104 in harsh or outdoorenvironments creates a need for protection circuitry 100 that protectsagainst dangerous current scenarios resulting from the potential failureor misuse of components in an electric grill 510. The environmentalconditions—including sun, rain, wind, cleaning agents, food stuffs, andthe like—may degrade electrical components and lead to short circuits,leaking current, or other dangerous conditions. In some instances,components may be permanently degraded. In other instances degradedcomponents, such as heating elements 103, 104, may return to normalcondition if they are cleaned or re-installed. In both instances, thereis a need to restrict the flow of current to protect the user.

Protection circuitry 100 may protect against various failure scenarios,including, without limitation, instances of ground fault; overcurrent;driver failure; and failure of the microprocessor 113. For example, aground fault (or unbalanced current) occurs when the current drawn by adevice such as electric grill 510 does not match the current returned bythe device to the wall outlet. Often times, this indicates a currentleakage. Leaking current creates a hazard to a user, especially if thecurrent reaches the electric grill's housing 506. In that case, the usermay be shocked. In another failure scenario, degraded components maycause the electric grill 510 to draw an unsafe current load, leading toa so-called “overcurrent.” That may result in component damage andeventually lead to leaking current. In yet another failure scenario, aheating element 103, 104 may receive a current load that is notnecessarily unsafe, but is inconsistent with the heating element'soperating mode. This inconsistency suggests a driver failure, which inturn may lead to unsafe conditions. A further failure scenario involvesthe failure of the microprocessor 113. Because the microprocessor 113controls the current delivered to the heating element(s), its failurecould potentially lead to unpredictable current loads. Aspects of thepresent invention are designed to disable current in the event one ormore failure scenarios (including those identified above) arerecognized.

FIGS. 1-10 show preferred embodiments of an electric grill 510 and apreferred protection circuity 100. By way of example, FIGS. 1A and 1Bshow a representative electric grill and some of its major components.FIG. 1A shows a preferred exterior of electric grill 510, including ahousing and lid 506, onto which left and right control knobs 501 and502, as well as display 503, may be mounted. The electric grill 510includes a power cord 507 for connecting to an AC wall outlet. Left andright control knobs 501 and 502, and display 503, connect to amicrocontroller 113 which is described in greater detail herein. A resetbutton 511 may also be provided for use as hereinafter described.

As shown in FIG. 1B, left and right control knobs 501 and 502 may beassociated with a first and second heating element, 103 and 104,respectively, thus creating dual cooking zones. A representative grateor cooking surface 512 is also shown in FIG. 1B. Each heating element103, 104 may be controlled independently by a knob 501, 502 or othercontroller or user input associated with the heating element 103, 104.Left knob 501 and right knob 502 may be positioned on the exterior of agrill housing 506. The knobs 501 and 502, or any other input device thatwill be understood by those of skill in the art, may be connected to amicroprocessor 113 to set the operating mode of one or more heatingelements 103, 104. Although FIGS. 1A and 1B show two knobs 501, 502controlling two heating elements 103, 104, it should be understood thatprotection circuitry 100 may be used with any combination of user inputdevices and heating elements, as will be understood by those of skill inthe art.

Using knobs 501 and 502, or any other input device, a user typicallyselects an operating mode for one or both heating elements 103 and 104.The operating mode may include a desired temperature setting.Microprocessor 113, described in further detail herein, controls theelectric current delivered to heating elements 103 and 104 in order toachieve the desired temperature setting. Microprocessor 113 can achievea desired temperature for each heating element 103 and 104 using afeedback loop in which it receives a current or real time temperaturereading from thermocouples 121 and 122, which may be proximallypositioned by respective heating elements 103 and 104. It should beunderstood that, although thermocouples are shown as an example, anyknown temperature sensing device may be used. A person of ordinary skillin the art would recognize that various types and numbers of knobs,touch-pad, heating elements, temperature sensors and/or displays may beused.

The electric grill 510 preferably includes a display 503 and/or otheruser interface. The display 503 may be connected to microprocessor 113and display information relating to the current settings or operation ofone or more of the heating elements 103, 104. For example, the display503 may show the current temperature of heating elements 103 and 104 (asmeasured by thermocouples 121 and 122), as well as the desiredtemperature a user has selected via knobs 501 and/or 502.

A preferred embodiment of protection circuitry 100 is shown in FIGS. 2and 7, where perforated lines represent control/data lines while solidlines represent power lines. In general, non-limiting terms, FIG. 2shows hardware components and a specially configured microprocessor thatcan detect various failure conditions and respond by disabling the flowof current to the electric grill 510. Protection circuitry 100 includesa current transformer 105 for measuring a potential difference, if any,between current drawn by the device and current returned from thedevice. A ground fault detection unit 117 is provided to evaluate thedifference, if any, and activate a trip controller 118, which wouldcause a latch relay 106 and/or 107 to create an open circuit and thusstop the flow of current. Moreover, a microprocessor 113 receivescurrent readings from a Hall Effect sensor 119 and may use those currentreadings to detect various types of dangerous conditions. If a dangerouscondition is detected, microprocessor 113 may activate the tripcontroller 118 to create an open circuit, or disable triac drivers 111and/or 112 in order to prevent current from flowing to heating elements103 and/or 104. A watchdog monitor may optionally be provided tocommunicate with microprocessor 113 and to disable triacs 108 and/or 109in the event microprocessor 113 is not communicating normally.

Line 101 and neutral 102 may draw alternating current (AC) from atypical wall outlet. A traditional power cord 507 may be used to plugline 101 and neutral 102 into an AC wall outlet using typical fixtures.Line 101 and neutral 102 also connect to a set of one or more AC/DCpower converters 114 which supply the basic power needs of variouscomponents including display(s) and/or microprocessor(s). The powerconverters 114 convert the alternating current to direct current havinglines of 3.3 Volts DC, 5 Volts DC, and 15 Volts DC. These DC lines maybe used to power various components on the electric grill, such as oneor more displays, microprocessor(s), etc. A person of ordinary skillwould recognize that the AC/DC power converters 114 can be used tosupply any level of DC voltage required by any of the electric grill'scomponents.

Line 101 and neutral 102 further connect to current transformer 105,which measures the difference, if any, between current going to heatingelements 103 and/or 104 from line 101, and current returning to neutral102. A potential difference in current, if any, is signaled to groundfault detection unit 117, which evaluates the difference in current todetermine if current is leaking. In other words, if damage to thecircuit (whether temporary or permanent) has caused electric current toleak from any of the components, then the current returning throughneutral 102 will be less than the current drawn in line 101. Groundfault detection unit 117 detects that there is electric current missing.Missing current is indicative of a dangerous operating condition becauseit may come in contact with the user, causing an electric shock, orcause other components to fail.

In such a scenario, a desired response is to stop the flow of anycurrent in order to avoid the risk of shock, electrocution or componentdamage. To cause current to stop flowing, ground fault detection unit117 activates a trip controller 118, which in turn openselectro-mechanical latches 106 and 107. As shown in FIG. 2, latches 106and 107 are positioned in series with heating elements 103 and 104;thus, tripping a latch causes an open circuit, which, by definition,stops the flow of current. Latch relays 106 and 107 may beelectro-mechanical switches for creating an open circuit and may beconnected via a control line to trip controller 118. When tripped, latchrelays 106 and 107 may remain open until a user engages a mechanicalswitch. As one example, a reset button 511 or other mechanical switch onthe housing 506 may be associated with the latch relays 106 and 107 toreset them into a closed position after they have been tripped.

An exemplary embodiment of ground fault detection unit 117 interactingwith latch relays 106 and 107 is best shown in FIG. 4. As a non-limitingexample, ground fault detection unit 117 may be a ground faultinterrupter such as part number FAN4146ESX, made by FairchildSemiconductor. The current transformer 105 is positioned to measure thecurrent difference, which is read by ground fault detection unit 117.Ground fault detection unit 117 generates a trip control signal 401 ifthe current difference exceeds a safety threshold, in which case tripcontrol signal 401 is fed back to latch relays 106 and 107, creating anopen circuit and stopping the flow of current. A user turning on adevice in which current is leaking will be protected because thetripping of latch relays 106 and 107 will cause an open circuit, therebyminimizing the risk of electric shock to the user or further damage tothe equipment. A person of skill in the art would recognize that acertain tolerance in current difference may be allowable.

Again by reference to FIG. 2, a step-down transformer 115 is providedbecause ground fault detection unit 117 operates at a lower voltage thanthat drawn from line 101 and neutral 102. Line 101 and neutral 102 areconnected to step-down transformer 115, which provides a lower secondaryvoltage through a full wave rectifier 116 to ground fault detection unit117 and also to a trip controller 118. The step down transformer 115 hasthe benefit of isolating the ground fault detection unit 117 and tripcontroller 118 from the high voltage of line 101 and neutral 102.Instead, they operate at the lower secondary voltage. A person of skillin the art would recognize that step-down transformers are used toisolate components operating at a lower voltage. Step down transformer115 has the additional benefit of separating ground fault detection unit117 from microprocessor 113, which provides added protection in theevent that microprocessor 113 fails during a ground fault/unbalancedcurrent. Microprocessor 113's failure would not prevent ground faultdetection unit 117 from recognizing a ground fault/unbalanced current.Likewise, a failure of ground fault detection unit 117 would not preventmicroprocessor 113 from continuing to monitor current conditions.

During normal operation, microprocessor 113 controls the heat andtemperature setting by controlling the flow of electricity to heatingelements 103 and 104. Microprocessor 113 may also be configured todetect and respond to abnormal operating conditions, i.e. conditionshaving an increased risk of electrocution, shock or component damage. Adiscussion of microprocessor 113's functionality during normal operatingconditions is provided, followed by specific configurations that allowmicroprocessor 113 to detect and respond to failure conditions.

During normal operating conditions, microprocessor 113 controls theelectricity (and thus, the heat and temperature) to heating elements 103and 104 from line 101 and neutral 102. The electric path runs throughline 101 and neutral 102, which are connected through currenttransformer 105, and further through a series of latch relays 106 and107 and triacs 108 and 109. As will be understood, triacs are threeelectrode devices, or triodes, that conduct alternating current. Triacsare a type of solid state bidirectional switch. The protection circuit100 disclosed herein describes the use of triacs to control currentflowing to heating elements 103 and 104, however it will be understoodthat other solid state bidirectional switches may be used in place of atriacs consistent with the present inventions. Heating elements 103 and104 may be resistive heaters which increase in temperature as morecurrent passes through them. Other types of heating elements 103, 104may also be used as will be understood by those of skill in the art.

Triac drivers 111 and 112 control triacs 108 and 109 by “opening” and“closing” them to allow or prevent current from passing to heatingelements 103 and 104. A person of ordinary skill in the art wouldrecognize that triac drivers are used to control a high voltage triacwith a low voltage DC source (such as a microprocessor) (FIG. 2).Moreover, triac drivers 111, 112 are used to isolate devices from apotentially high current or voltage in a triac. Triac drivers 111 and112 interface between microprocessor 113 and triacs 108 and 109 while atthe same time keeping microprocessor 113 isolated from voltages andcurrents in triacs 108 and 109.

In order to achieve a user's desired temperature during normaloperation, microprocessor 113 controls current delivered to the heatingelements 103 and 104 by activating (or deactivating) triacs 108 and 109via their triac drivers 111, 112. In other words, microprocessor 113controls the current drawn, and thus the temperature, of heatingelements 103 and 104 by controlling the triac drivers 111 and 112. Adisabled triac 108 and/or 109 creates an open circuit through which nocurrent can flow.

To recognize when a desired temperature has been achieved,microprocessor 113 may receive temperature feedback from one or morethermocouples 121 and 122 located proximately to each heating element103 and 104, or elsewhere throughout the cook box. FIG. 1B shows arepresentative example of thermocouples 121 and 122 adjacent to eachheating element 103 and 104. The feedback is used by microprocessor 113to adjust the current delivered to the heating elements 103, 104 untilthe desired temperatures selected by knobs 501 and/or 502 is achieved.As a result, a user can select a desired operating mode (independently)for heating elements 103 and 104 and microprocessor 113 will control thecurrent delivered until a desired temperature setting is reached.

FIG. 5 shows exemplary inputs and outputs to and from microprocessor113, which can use the feedback from the thermocouple 121 and/or 122 toadjust current flowing to a heating element 103 and/or 104 until adesired temperature is reached. The desired temperature may be selectedby a user through a user interface, such as knobs 501 or 502, andcommunicated electronically to microprocessor 113. A person of ordinaryskill in the art would know understand that the microprocessor 113 mayinclude and communicate with an internal or external memory 508containing the software instructions for executing the calculations andcomparisons, as well as other settings described herein.

As an optional input example, microprocessor 113 may receive a controlsignal from a zero crossing detection unit 110 (FIG. 2). The zerocrossing detection unit 110 sends a control signal each time thealternating current, as measured through step down transformer 115,crosses zero. Using this signal, microprocessor 113 can identify thepresent status of an alternating current's wave form. Tracking the zerocrossings enables microprocessor 113 to turn triacs 108 and 109 on andoff in a manner that reduces the harmonics introduced.

Microprocessor 113 may be configured to identify dangerous conditionsthat arise during normal operation. Although ground fault detection unit117 detects a leaking current, there are other dangerous conditions thatmicroprocessor 113 is specifically configured to detect and respond to.As seen in FIG. 2, microprocessor 113 is in communication with tripcontroller 118 and triac drivers 111 and 112, thus giving microprocessor113 two different ways to stop a flow of current—by tripping a latch 106or 107, or by disable triacs 108 and/or 109 if it detects a failurecondition. For example, FIG. 3 shows that heating elements 103 and 104are in series with triacs 108, 109 and with latches 106, 107. As apractical matter, opening one of the latches 106, 107 or both of thetriacs 108, 109 will stop the flow of all current.

As one example, microprocessor 113 may be configured to respond to an“overcurrent” scenario. Overcurrent conditions are dangerous becausethey are associated with an increased risk of component failure and/ordamage to electronic circuitry, which in turn may be a precursor tocurrent leakage. An overcurrent scenario occurs when a circuit drawsmore current than it is safely rated to handle. An overcurrent may occurif a harsh environment causes the resistance value of some components,such as heating elements, to change, resulting in a higher current draw.However, an overcurrent scenario does not necessarily correlate to amismatch in current. Therefore, ground fault detection unit 117 may notdetect an overcurrent and it may be desirable to configuremicroprocessor 113 to recognize it. To that end, a Hall Effect Sensor119 sends microprocessor 113 a current reading indicative of the currentflowing through triacs 108 and 109. A Hall Effect sensor 119 measuresthe current being delivered through one or more of the triacs and toheating elements 103 and 104. The protection circuitry described hereindiscloses a Hall Effect sensor 119 that is used to measure current, buta person of skill in the art would recognize that any suitable currentsensor may be used in place of Hall Effect sensor 119. The Hall Effectsensor 119 is connected to microprocessor 113 via a control line toconvey to microprocessor 113 how much current is being delivered throughthe heaters 103, 104.

The Hall Effect sensor 119 measures the current delivered to heatingelements 103 and 104 and sends a current measurement to microprocessor113 via a control/data line. The Hall Effect sensor 119 may beconfigured to measure the current through the voltage line 101, or tomeasure both of the two currents going to the individual heatingelements 103 and 104. In either configuration, the current reading iscommunicated to the microprocessor 113. FIGS. 2 and 5 show a connectionbetween microprocessor 113 and Hall Effect sensor 119. FIG. 6 showsmicroprocessor 113 sending a trip control signal if it detects anovercurrent condition. In FIG. 2, Hall Effect Sensor 119 is shown tomeasure the combined current in the power line leading to triac 108 and109. A person of ordinary skill in the art would recognize that apossible alternative configuration would be to connect one Hall Effectsensor to the node of each triac, thereby measuring the current to eachindividual triac rather than the combined current.

To recognize an overcurrent condition, microprocessor 113 compares thecurrent reading from Hall Effect Sensor 119 with a predeterminedthreshold current level at which the circuit may safely operate. Thepredetermined threshold is the threshold for an overcurrent condition.The predetermined threshold current level may be chosen based on anynumber of considerations, including the maximum current at which theheating element 103, 104 may operate, or the maximum current at whichany of the other components in the circuit may operate. Microprocessor113 compares the current measured by Hall Effect sensor 119 to thepredetermined threshold current level. If the current exceeds thethreshold, there exists a potential overcurrent condition and the flowof current should be stopped. To stop the flow of current,microprocessor 113 sends a trip control signal 505 to trip controller118, which is connected via control/data line. Trip controller 118responds by tripping latch relays 106 and 107, causing an open circuitwith respect to the heating elements and thereby stopping the flow ofcurrent. Exemplary inputs from the Hall Effect sensor 119 tomicroprocessor 113, and the trip control signal 505 from microprocessor113, are shown in FIG. 5.

In some embodiments, microprocessor 113 may additionally be configuredto recognize when heating elements 103 and 104 draw a current that iswithin a safe range, but which is different from the current expected tobe drawn given a heating element's selected operating mode. For example,a potentially dangerous scenario may occur when a heating element is setto a “LOW” temperature but drawing current reserved for a “HIGH”temperature, or vice versa. If a user has set a heating element 103and/or 104 to a high temperature, but only a low current is beingdelivered, it is likely a component has failed. Possible causes of sucha scenario include, without limitation, a harsh or caustic environmentcorroding Hall Effect sensor 119 or a failure of triacs 108, 109 ortriac drivers 111, 112.

Microprocessor 113 may use a feedback loop from thermocouples 121 and122 to deliver current to a heating element 103 and/or 104 until adesired temperature is achieved. The desired temperature may then bemaintained at a steady state. A person of ordinary skill would recognizethat raising the temperature of a heating element 103 or 104 draws morecurrent than maintaining the temperature. By way of example, if a useractivates electric grill 510 and selects a “HIGH” temperature,microprocessor 113 must deliver a high current to the relevant heatingelement 103 and/or 104 until a “HIGH” temperature has been achieved.Once microprocessor 113 recognizes that the desired “HIGH” temperaturehas been achieved (for example via feedback from thermocouples 121 and122), microprocessor 113 can reduce the current delivered in order tomaintain the temperature at a steady state.

Examples of how the heating elements may operate include discrete modes,such as “HIGH,” “MEDIUM,” “LOW,” or on a continuous spectrum measuredfor example in % or by a temperature. Since a higher current results ina heating element having higher temperature, a person of skill in theart would recognize that raising the temperature of heating elements 103and 104 would draw more current than maintaining a steady statetemperature.

To identify an unexpected current condition, microprocessor 113 isconfigured to compare a current reading from Hall Effect sensor 119 withan expected current. The current which microprocessor 113 is configuredto deliver to the heating elements in any given mode (accounting forwhether microprocessor 113 is raising a temperature or maintaining asteady state) is the “expected current” because it is expected to matchthe reading from Hall Effect sensor 119 during normal operatingconditions. In other words, during normal operating conditions, thecurrent reading from Hall Effect sensor 119 is expected to match theexpected current, i.e. the current microprocessor 113 is programmed todeliver. If the current reading from Hall Effect sensor 119 does notmatch the expected current, it is likely that a driver failure hasoccurred.

The expected current value may be accessible to microprocessor 113through internal or external memory 508. In this way, microprocessor 113is programmed to recognize the total amount of current that should bedrawn by a normally-functioning heating element or elements in any givenoperating mode (or combinations of operating modes).

Should a failure condition arise, microprocessor 113 responds bydisabling triac drivers 111 and 112, thereby opening the respectivetriacs and cutting current through the heating elements 103 and/or 104.In one embodiment, microprocessor 113 may optionally be programmed tore-enable the flow of current after a predetermined amount of time haspassed, and to continue monitoring the current drawn. Re-enabling theflow of current may be desirable because the cause of the failure mayhave been temporary. By way of non-limiting example, a temporary failurecondition that quickly stabilizes may be detected if the electric grill510 was recently turned on/off, or if a temporary irregularity occurredin the power grid.

FIG. 6 is a flow chart showing microprocessor 113 determining anexpected current based on the electric grill's 510 operating mode, andcomparing the expected current to an actual current reading receivedfrom the Hall Effect sensor 119. If a mismatch is detected, triacdrivers 111 and 112 are disabled. Moreover, FIG. 6 also showsmicroprocessor 113 comparing a current reading from the Hall Effect 119sensor to an overcurrent threshold, and responding to an overcurrentcondition by sending trip control signal 505. A person of ordinary skillin the art would recognize that these steps and comparisons could beperformed in any order and in a number of different implementations, allof which are contemplated by the present inventions. Microprocessor 113may repeat these operations on any desired or periodic basis.

In yet another failure example, protection circuit 100 protects againsta failure of microprocessor 113. Because microprocessor 113 controlscurrent delivered to heating elements 103 and 104, its failure couldlead to unpredictable results that may include unsafe levels of current.To protect against a failure of microprocessor 113, the circuit 100 mayinclude a watchdog monitor 120 connected between microprocessor 113 andtriacs 108 and 109 as shown in FIG. 2.

In this situation, microprocessor 113 sends a watchdog monitor signal504 to watchdog monitor 120 which confirms that microprocessor 113 isoperating normally. Watchdog monitor 120 is configured to look for asignal from microprocessor 113 confirming its normal operation. Watchdogmonitor 120 is also connected to triacs 108 and 109. In the absence of asignal from microprocessor 113 confirming normal operation, watchdogmonitor 120 disables the triacs 108 and 109, thus preventing currentfrom flowing to them. If microprocessor 113 subsequently returns tonormal operation, watchdog monitor 120 may re-enable the flow ofcurrent. This configuration of watchdog monitor 120 allows thepossibility that microprocessor 113 may return to normal operation aftera period of malfunction or resetting. This is advantageous because itallows for continued operation even in scenarios where themicroprocessor 113 is booting or rebooting. In other words, if themicroprocessor 113 is in the process of rebooting (intentionally, orunintentionally), watchdog monitor 120 may determine that microprocessor113 is not operating normally and disable the flow of current. Butnormal operation may resume once microprocessor 113 completes its bootsequence and resumes sending its signal to watchdog monitor 120.

FIG. 7 shows additional embodiments of the inventions. For example,shown in FIG. 7 is an embodiment in which zero crossing detection unit110 is connected directly to line 101 and neutral 102, without anyintermediary transformer. Also shown is an embodiment in which groundfault detection unit 117 is connected to power (in this case, 12 V, butother voltages are also contemplated) through the AC/DC power converters114. Zero crossing detection unit 110 and ground fault detection unit117 may perform the functions described herein when configured as shownin FIG. 2, FIG. 7, or any other number of configurations.

FIG. 7 further discloses relays 701 and 702, which are configured inparallel with TriACs 108 and 109, respectively. Relays 701 and 702 arecontrolled via control line (not shown) by microprocessor 113 forcontrolling the delivery of current to heating elements 103 and 104,respectively. Because of the parallel configuration between relays 701,702 and TriACs 108, 109, current can be delivered to the heatingelements 103, 104 by activating either a relay or a TriAC. Statedanother way, microprocessor 113 can use either the respective TriAC 108,109 or the respective relay 701, 702 to deliver current to heatingelements 103, 104.

An advantage of having two components (a relay and a TriAC) which caneach deliver current to the heating elements 103, 104, is thatmicroprocessor 113 can alternate between the two components to reduceheat generation. For example, delivering 100% power to heating elements103, 104 may cause TriACs 108, 109 to overheat when active. Morespecifically, heating elements 103, 104 may draw a relatively highamount of current when a high temperature is desired, and deliveringsaid current through TriACs 108, 109 for a prolonged period of time maycause TriACs 108, 109 to overheat and eventually deteriorate. To avoidthis, microprocessor 113 may deactivate TriACs 108, 109 and insteadactivate relays 701, 702 when delivering a “HIGH,” or relatively highcurrent to heating elements 103, 104. Current then flows to heatingelements 103 and/or 104 through relays 701 and/or 702, respectively,thereby protecting TriACs 108, 109 from overheating.

FIG. 7 further shows an embodiment of microprocessor 113 having thefunctionality of band controller 703. A person of skill in the art,having the benefit of this disclosure, would understand that bandcontroller 703 may be a physical and/or virtual subcomponent ofmicroprocessor 113, or may alternatively be a separate hardware and/orsoftware component. In embodiments of the inventions, band controller703 may be configured to receive a target temperature via a user input(including wireless inputs), and to control the amount of power (i.e.current) delivered to heating elements 103, 104 to achieve theuser-selected target temperature.

Band controller 703 may use hardware and software applications toachieve and maintain target temperatures at heating elements 103, 104 bycontrolling the amount of current delivered. Band controller 703 mayreceive feedback from thermocouples 121, 122, which may be positionedproximate to heating elements 103, 104, and use such feedback todetermine when a target temperature has been achieved. In embodiments ofthe inventions, it may be desirable to estimate the ambient temperaturewithin the grill's cook box using thermocouples 121, 122. There arescenarios in which the ambient temperature (e.g. the temperature at aposition of six or eight inches above the heating elements) may not beidentical to the temperature at heating elements 103, 104, especiallywhen operating at higher temperatures. Because food may be positionedthroughout a grill's cook box, for example on a grate positioned a fewinches above heating elements 103, 104, it may be desirable for bandcontroller 703 (and microprocessor 113) to operate based on an estimatedambient temperature, rather than the temperature at heating elements103, 104. Operating based on the ambient temperature provides a moreprecise measurement of a food's temperature, and therefore a moreprecise measurement of a food's doneness.

By way of example, FIG. 10 shows Applicants' test data for accuratelyestimating the ambient temperature 1001, based on the temperature 1002at thermocouples 121, 122. On its x-axis, FIG. 10 shows a temperature1002 measured at thermocouples 121, 122. On its y-axis, FIG. 10 shows acorresponding estimated ambient temperature 1001. The curve 1003 showsthe estimated ambient temperature (y-axis) as a function of the measuredtemperature (x-axis). The estimated ambient temperature of FIG. 10 wasmeasured a few inches above a heating element, at a position where auser may configure a cooking grate. It becomes clear that, at highertemperatures, the ambient temperature diverges from the measuredtemperature at the thermocouples—in other words, at higher temperatures,the estimated ambient temperature at a position above a heating elementrises faster than the temperature of the heating element. By way ofexample, at reference point 1004, the estimated ambient temperature andthe temperature at the thermocouples 1002 are both roughly equal, at 150F. At a higher temperature (e.g. reference point 1005), the temperatureat the thermocouple may be 300 F, whereas the estimated ambienttemperature has risen to approximately 400 F. Thus, at highertemperatures, a higher offset is required in order to accuratelyestimate the ambient temperature.

Using the offsets indicated by FIG. 10, microprocessor 113, and/or bandcontroller 703, may be adapted and configured with hardware and/orsoftware to calculate an estimated ambient temperature based on ameasured temperature at thermocouples 121, 122. It should be understoodthat the offsets of FIG. 10 are provided as an example only, and may beincreased or decreased depending on factors such as the height of acooking grate, and other factors which may affect ambient conditions.Moreover, microprocessor 113 and/or band controller 703 may use such anestimated ambient temperature as part of a feedback loop to determinewhen a target temperature is reached. In other words, in someembodiments, a target temperature may refer to the estimated ambienttemperature, and in other embodiments it may refer to the temperature atthermocouples 121, 122.

It is contemplated that yet further embodiments may use a food probe(not shown) to measure a food's temperature and determine when a targettemperature is reached based on a temperature reading from the foodprobe. A food probe is a temperature sensing device which may beinserted by a user into a food—such as a steak or a chicken breast—tomeasure the food's internal temperature. Using a food probe to sensetemperature may be advantageous to some cooking styles because it canprovide an accurate determination of a food's internal temperature, andby extension its doneness.

To consistently maintain a target temperature, band controller 703 maydetermine temperature “bands” surrounding a given target temperature,where said bands indicate the amount of power (i.e. current) to deliverto a heating element 103, 104 as a target temperature is approached. Inembodiments of the inventions, the bands create zones representing 0%,50%, and 100% power. The zone above 801 represents a temperature zone inwhich 0% power is delivered; the zone between 801 and 803 represents azone in which 50% power is delivered, and the zone below 803 represents100% power delivery. Band controller 703 uses the bands to determine anappropriate power (e.g. electric current) to deliver to a heatingelement to achieve and maintain the desired target temperature. By wayof example, seen for example in FIG. 8A, band controller 703 may deliver100% power until a desired target temperature 802 is achieved, and thenreduce power to 50% until an upper band 801 is reached. If the upperband 801 is exceeded, band controller 703 reduces power to 0%. If thetemperature drops to (or below) a lower band 803, power is againincreased to 100%. Band controller 703 continuously receives feedbackfrom thermocouples 121, 122, and compares the feedback (in someembodiments, the estimated ambient temperature described above) toappropriate temperature bands. In this way, temperature fluctuatesbetween lower band 803 and upper band 801, and approximates the targettemperature.

Moreover, in embodiments of the invention, band controller 703dynamically shifts the bands depending on the desired targettemperature. Dynamically shifting the temperature bands allows for moreprecise temperature control, allowing a user to approximately maintainthe selected target temperature. This occurs because, at lowertemperatures, a 50% power setting may cause the electric grillstemperature to continue increasing past the desired target temperature.On the other hand, at higher temperatures, delivering 50% power maycause the temperature to begin dropping below the desired targettemperature. Therefore, band controller 703 may compensate by loweringthe bands for a lower desired target temperature. On the other hand, ata higher temperature range, band controller 703 may shift the bandshigher. An example of lowered temperature bands corresponding to a lowerdesired target temperature is shown in FIG. 8B. In FIG. 8B, a lowertarget temperature has been selected, and band controller 703 shiftedthe upper band (801) to correspond to the target temperature.Conversely, FIG. 8C shows a relatively high target temperature, forwhich band controller 703 raised the power bands such that the targettemperature 802 coincides with the lower band (803). In FIG. 8B, thetarget temperature overlaps with the power band 801; whereas in FIG. 8Cthe target temperature 802 overlaps with the power band 803. Exemplaryvalues for power bands are provided in the following table:

Desired target Lower temperature Upper temperature temperature (T) band(100%) band (0%) T < 250 F. T − 25 F. T 250 F. < T < 400 F. T − 10 F.T + 10 F. 400 F. < T T T + 15 F.

In embodiments having multiple heating elements capable of independentoperation, users can input multiple target temperatures. For example, anembodiment having two independent heating elements 103, 104, may receivetwo separate target temperatures, each corresponding to one heatingelement. Target temperatures may be communicated to band controller 703through any number of possible user inputs. By way of non-limitingexamples, possible user inputs include knobs 501, 502. User inputs canalso be received wirelessly, via wireless controller 704, from awireless device configured to communicate with wireless controller 704.In such an embodiment, wireless controller 704 may be configured towirelessly communicate with a remote device via Wi-Fi, Bluetooth, radiofrequency, or any other form of wireless communication. Remote devicesinclude cell phones, tablets, laptops, computers, and any other form ofdevice capable of wireless communication. FIG. 9 shows an exemplaryremote device 901, having a display 902 and user input device 903,communicating with the electric grill 510's wireless controller 704. Ina non-limiting example, remote device 901 may be a cell phone with atouch screen as its input device 903. Regardless of the type of deviceused, it is contemplated that remote device 901 may be configured toreceive a user input representing, among other things, one or moretarget temperatures, and wirelessly communicate said target temperatureto electric grill 510 via wireless controller 704.

In exemplary embodiments, remote device 901 may be adapted andconfigured to directly receive a desired target temperature from a user.In such embodiments, a user can use input device 903 to select a targettemperature. In other exemplary embodiments, remote device 901 may beadapted and configured to receive a user input selecting a type of meatto be cooked, and a desired doneness, and to determine the appropriatetarget temperature for the user's selection. In such embodiments, remotedevice 901 may have a memory 904 storing the appropriate targettemperature associated with a desired food profile. A user thus usesinput device 903 to select a food profile, and remote device 901wirelessly communicates the associated target temperature. In additionto controlling target temperatures, embodiments of remote device 901 areadapted and configured to send an “on” and/or “off” signal wirelessly,via wireless controller 704, to microprocessor 113 and/or bandcontroller 703. As such, a user can control both the desired targettemperature of the electric grill 510, as well as turning it on and off.

Additional examples of wireless communication between remote device 901and electric grill 510 (via wireless controller 704) include the abilityto control settings for display 503 remotely, from remote device 901.Thus, remote device 901 may be adapted and configured to wirelesslycontrol the information displayed on electric grill 510's display 503.Remote device 901 may control which information is displayed on display503, and allow a user to toggle between (C) Celsius and (F) Fahrenheitwith respect to temperature measurements. Such information may includethe electric grill 510's current temperature, ambient temperature,target temperature, as well as timers indicating how long the grill hasbeen active, how long a food has been cooking, or how much time remainsuntil a food reaches its target temperature. Such information mayfurther be wirelessly transmitted from electric grill 510, via wirelesscontroller 704, to remote device 901.

In turn, remote device 901 may provide such information to a user on aremote device display 902, and may further use said information towirelessly turn electric grill 510 off, or reduce its desired targettemperature, if a predetermined temperature has been reached, or if afood has been cooking for a predetermined time period. In exemplaryembodiments, food profiles are stored in memory 904, where such foodprofiles indicate either the appropriate target temperature and/or anappropriate cooking time for a given food. Remote device 901 may monitorinformation received wirelessly from electric grill 510 and determine ifan appropriate temperature or cooking time has been reached. Remotedevice 901 may also be adapted and configured to turn off electric grill510 once that happens, and/or to provide an audible or visual alert.Such an audible and/or visual alert may be provided on the remote device901, at the electric grill 510, or both.

Moreover, it is contemplated that embodiments of the inventions may usewireless communications to deliver error codes from the electric grill510 to a remote device 901, where said error codes may be indicative ofan unsafe current condition as described further herein. Deliveringerror codes to a remote device 901 has the advantage of allowing a userto remotely understand when an unsafe current condition has occurred,and remote device 901 may further display safety tips for correcting theunsafe current condition as well as recording the conditions that leadto the unsafe condition.

Error codes may be determined by microprocessor 113 acting inconjunction with the protection circuitry 100. As described furtherherein, microprocessor 113 may be in communication, via control lines,with Ground Fault Detection Unit 117 and Hall Effect sensor 119. Thus,microprocessor 113 may be adapted and configured to receive a controlsignal from Ground Fault Detection Unit 117 indicating that a groundfault has been detected. Likewise, microprocessor 113 may be adapted andconfigured to use signals from Hall Effect sensor 119 to recognizeerrors in delivering current to heating elements 103 and 104. Asdescribed further herein, a reading of zero current from Hall Effectsensor 119 indicates that heating elements 103 and 104 are not receivingany current, whereas an unexpectedly high current reading indicates thattoo much current is flowing to heating elements 103 and 104 (e.g. an“over-current” scenario).

In embodiments of the inventions, microprocessor 113 is adapted andconfigured to recognize these errors and wirelessly communicate, viawireless controller 704, an error code corresponding to the error whichoccurred. For example, an error code of “01” may indicate that a groundfault has been detected; “02” may indicate that Hall Effect sensor 119has determined that no current (or an unexpected current) is flowing toheating elements 103 and/or 104; and “03” may indicate that Hall Effectsensor 119 detected an unexpectedly high current flowing to heatingelements 103 and/or 104. In embodiments where microprocessor 113 is achip including a “self-check” feature, an error code of “04” may be sentif the self-check pin determines a failure of microprocessor 113. Aperson of ordinary skill in the art would recognize that any variety ofcodes may be used to indicate each error. In response to an error, anaudible or visual alert may be signaled at electric grill 510, includingfor example on display 503. Likewise, remote device 901 may also providean audible or visual alert upon receiving an error code.

Remote device 901 may be adapted and configured to wirelessly receiveerror codes and display, on display 902, a message identifying the typeof error to the user. Such an error message may be accompanied by anaudible or visual alert at remote device 901. Remote device 901 mayfurther be adapted and configured to display a message, saved in memory904, explaining steps that a user should take to correct the error. Forexample, as explained further herein, protection circuitry 100 may beconfigured to trip a relay 106 and/or 107 in response to a ground fault.Therefore, if microprocessor 113 sends an error code (e.g. “01”)indicating a ground fault to remote device 901, remote device 901 maydisplay a message alerting a user that a ground fault has occurred andprompting the user to reset relay 106 and/or 107.

In response to an error “02,” remote device 901 may be adapted andconfigured to alert the user that no current is flowing to heatingelement 103 and/or 104. The absence of current flowing may be indicativeof an open circuit, which may occur, for example, if a heating element103, 104 is not properly installed. Thus, remote device 901 may displaya message prompting a user to uninstall, and re-install, heatingelements 103, 104. If the error persists, remote device 801 may promptthe user to contact the manufacturer.

Similarly, if error code “03” is received, an over-current has occurred.One possible cause of an over-current may be that a user has installedan incompatible, or faulty, heating element having an incorrectresistance value. (A heating element with an incorrectly low resistancewill cause an inappropriately high current to flow through it). Forexample, a heating element designed to work at 120V would have aresistance value that is too low to function at 230V, causing anovercurrent. Thus, a user may be prompted to check the heating element,or replace it with a new one.

Remote device 901 and/or microprocessor 113 may create a log of errorsand store the error log in a memory. Such an error log may include arecording of each error that occurred. Moreover, in embodiments whereremote device 901 receives status information (such as the temperatureof heating elements, ambient temperature, temperature targets, cookingtime, etc.) from electric grill 510, such status information may also berecorded in the error log. Status information may be deliveredcontinuously, or in response to an error. By way of example, it may beadvantageous to record how long a grill had been cooking before an erroroccurred, the grill's temperature at the time of an error, and otherrelated information. An error log may be helpful in diagnosing errors.It should be understood that the error log may be created and/or storedon the remote device 901, electric grill 510 (or microprocessor 113), orboth. A person of skill in the art would understand that a wide varietyof parameters may be recorded and stored as part of an error log.

In some embodiments, remote device 901 may have an internet connection905. Internet connection 905 allows remote device 901 to optionally senda recorded error log to a third party, such as an electric grill'smanufacturer. A manufacturer can therefore better understand the errorthat occurred and the conditions surrounding the error. This can lead toproduct fixes and improvements.

The present inventions also provide methods for reducing the risk ofunsafe electric conditions during grilling. In a preferred embodiment, auser may use an electric grill 510 to deliver current to one or moreelectric heating elements 103 and/or 104 which may be connected to avoltage line 101 and a neutral line 102 through triacs 108 and 109, andlatch relays 106 and 107. When heating element 103 or 104 is activatedby the user, a current transformer 105 in the electric grill 510'sprotection circuitry 100 measures a difference, if any, in the currentdrawn by electric grill 510 and the current returned from electric grill510. If a current difference is detected, methods of the presentinventions generate an electric signal to activate a trip controller 118connected to a latch relay 106 and/or 107.

Methods of the present inventions may additionally include using theelectric grill 510's protection circuitry 100 to measure current beingdelivered to a heating element 103 or 104 with a Hall Effect sensor 119and conveying the measured current to a microprocessor 113. Byactivating the electric grill 510 and its protection circuitry 100, themicroprocessor 113 compares the measured current to a predeterminedcurrent threshold. The predetermined current threshold may bedynamically selected based on the current operating mode selected by auser. If the measured current exceeds the predetermined threshold whilethe electric grill 510 is in use, the present inventions may include thestep of disabling the flow of current by tripping a latch relay 106and/or 107, or disabling a triac 108 and/or 109.

In additional embodiments, signals indicative of normal operation fromthe microprocessor 113 to a watchdog monitor 120 are sent. In turn,watchdog monitor 120 may enable triacs 108 and/or 109 to permit the flowof electricity to heating elements 103 and/or 104 during normaloperation, and disable the flow of electricity during a phase ofabnormal operation.

The devices and methods described above may be used to provide a saferelectric grill experience. Various embodiments allow a user to activatea knob 501 and/or 502 (or other input means, such as wireless) to grillfood using heat from heating elements 103 and/or 104, which in turn arecontrolled by a microprocessor 113. Display 503 may convey, among otherthings, the current temperature to the user to allow the user to decidewhen to put food onto a grate or how long to leave food cooking. A usermay be using an electric grill 510 that has been exposed to harshconditions for a prolonged period of time and which has electriccomponents that may leak current. Embodiments of the invention provide acurrent transformer 105 which functions together with ground faultdetection unit 117 and trip controller 118 to detect current leakageand, in response, trips latch relays 106 and 107. Although grilling willbe halted, the user will remain safe from the leaking current. A usermay respond, for example, by removing and re-installing heating elements103, 104, and pushing a reset button 511 or similar switch. Provided thecurrent leakage has been resolved, normal operation can continue.

During normal cooking, a heating element 103, 104 or other component maybecome unintentionally loose, or may be damaged from heat or otherenvironmental factors. A possible result is that electric grill 510 maydraw an unsafe current, which is detected by microprocessor 113 via asignal from Hall Effect sensor 119. The microprocessor 113 may respondby activating a trip controller 119 and thereby opening latches 106 and107. As described above, the result is a stoppage of current and theuser may attempt to restart the electric grill 510 via reset button 511.

Similarly, an unsafe condition may lead heater 103 and/or 104 to draw anamount of current that differs from the amount expected based on theuser settings of knobs 501 and/or 502. In response, embodiments of theinvention provide a microprocessor 113 which may disable triacs 108/109(via their drivers) to stop the flow of current. A user may be alertedvia display 503, but latches 106 and 107 are not tripped in this case,so in this instance, the user may not have to reset the button 511.

Further, embodiments of the invention may include a watchdog monitor 120which may be provided to monitor the correct operation of microprocessor113 while electric grill 510 is in use by a user. Watchdog monitor 120may disable triacs 108/109 if microprocessor 113 enters an abnormaloperating state, including a possible reboot. A user does not have toreset the button 511 and may wait for microprocessor 113 to return tonormal operation to resume grilling.

The hardware and specifically configured microprocessor may be providedto a user to ensure a safe grilling experience. A person of skill in theart would recognize that electric grills having various combinations ofthe embodiments described above are possible, and not every feature mustnecessarily be included in each embodiment. Moreover, although thepresent inventions have particular applicability to grills for outdooruse, it will be understood by those of skill in the art that the presentinventions may be used on a variety of grills or other devices, whetherfor indoor or outdoor use.

The present inventions also include methods for using a remote device901, such as a cell phone or tablet, to communicate with an electricgrill 510. For example, a user may use a cell phone to wirelesslycommunicate with electric grill 510 and activate it. Moreover, a useruses a remote device user input 903, such as a touch screen, to select atarget desired target temperature. In embodiments of the invention, auser may select a desired cooking profile, and remote device 901retrieves, from memory 904, the associated temperature, which iscommunicated wirelessly to microprocessor 113 and/or band controller703.

In response, microprocessor 113, and band controller 703, raise thepower delivered to heating elements 103, 104, until a desired targettemperature is achieved. Band controller 703 may be used to maintain atemperature within the range of predetermined bands. In this way, a usermay use electric grill 510 to cook a food item as long as no error hasoccurred at electric grill 510 (by extension, at protection circuitry100). During normal operations, the user may wirelessly receive statusinformation from electric grill 510 on remote device 901, includingvarious parameters concerning the temperature, time, and status of thegrill.

If an unsafe current condition occurs, microprocessor 113 may detect it,in accordance with the present disclosure, and send an error code to theuser at the user's remote device 901. An audible and/or visual alert maybe provided at electric grill 510 and/or remote device 901 to alert theuser that an unsafe current condition has occurred. Moreover, the usermay be presented with a message explaining the type of error which hasoccurred and providing suggestions for how to fix the error. Inembodiments of the invention, the user may opt to save an error log,which may contain the type of error that occurred as well as variousinformation surrounding the grill's operating conditions at the time ofthe error. The error log may then be sent over the internet to amanufacturer for further diagnoses and repair information.

The above description is not intended to limit the meaning of the wordsused in or the scope of the following claims that define the invention.Rather the descriptions and illustrations have been provided to aid inunderstanding the various embodiments. It is contemplated that futuremodifications in structure, function or result will exist that are notsubstantial changes and that all such insubstantial changes in what isclaims are intended to covered by the claims. Thus, while preferredembodiments of the present inventions have been illustrated anddescribed, one of skill in the art will understand that numerous changesand modifications can be made without departing from the claimedinvention. In addition, although the term “claimed invention” or“present invention” is sometimes used herein in the singular, it will beunderstood that there are a plurality of inventions as described andclaimed.

Various features of the present inventions are set forth in thefollowing claims.

What is claimed is:
 1. A system for monitoring a status of an electricgrill, comprising: at least one heating element connectable to a voltageline and a neutral line; a Hall Effect sensor configured to measurecurrent passing to said at least one heating element, a ground faultdetection unit configured to detect a ground fault error between thevoltage line and the neutral line; a wireless controller; and amicroprocessor, the microprocessor being in communication with the HallEffect sensor, the ground fault detection unit, and the wirelesscontroller; wherein the microprocessor is adapted and configured towirelessly send and receive signals to and from a remote device via thewireless controller.
 2. The system of claim 1, wherein themicroprocessor is adapted and configured to identify an overcurrenterror by comparing a current reading from the Hall Effect sensor to apredetermined current threshold, and to wirelessly send an error code tothe remote device in response to an overcurrent error.
 3. The system ofclaim 1, wherein the microprocessor is adapted and configured toidentify an unexpected current error by comparing a current reading fromthe Hall Effect sensor to an expected current, and to wirelessly send anerror code to the remote device in response to a current error.
 4. Thesystem of claim 1, wherein the microprocessor is adapted and configuredto receive a signal indicative of a ground fault error from the groundfault detection unit, and is further adapted and configured towirelessly send an error code to the remote device in response to aground fault error.
 5. The system of claim 1, wherein the microprocessoris connected to a relay or a triac driver for controlling the currentdelivered to the at least one heating element.
 6. The system of claim 5,wherein the microprocessor is adapted and configured to wirelesslyreceive an “off” signal from the remote device and, in response, todisable current from being delivered to the at least one heatingelement.
 7. The system of claim 1, further comprising a cook box and atleast one temperature sensing device for measuring a temperature insidethe cook box, wherein the thermocouple is in electronic communicationwith the microprocessor.
 8. The system of claim 7, further comprising adisplay in electronic communication with the microprocessor, wherein themicroprocessor is adapted and configured to display the temperature onthe display.
 9. The system of claim 8, wherein the microprocessor isfurther adapted and configured to toggle between displaying thetemperature in Celsius or Fahrenheit in response to a wireless signalfrom the remote device.
 10. The system of claim 7, wherein themicroprocessor is adapted and configured to wirelessly transmit thetemperature inside the cook box to the remote device.
 11. The system ofclaim 7, wherein the microprocessor is adapted and configured to recordoperating parameters of the electric grill and to wirelessly transmitthe operating parameters to the remote device.
 12. The system of claim11, wherein the microprocessor's transmission of operating parameters isadapted and configured to be continuous.
 13. The system of claim 11,wherein the microprocessor's transmission of operating parameters isadapted and configured to be in response to an error.
 14. The system ofclaim 11, wherein the operating parameters comprise a temperaturemeasurement.
 15. The system of claim 11, wherein the operatingparameters comprise a timer indicative of the amount of time the heatingelement has been active.
 16. A system for wirelessly monitoring anelectric grill's status, comprising: an electric grill having protectioncircuitry, the protection circuitry comprising a microprocessor inelectronic communication with a ground fault detection unit and a HallEffect sensor; and a wireless controller in electronic communicationwith the microprocessor; wherein the microprocessor is configured toreceive electronic signals from the ground fault detection unit and theHall Effect sensor; and wherein the microprocessor is further adaptedand configured to determine the occurrence of an error and, in response,wirelessly transmit, via the wireless controller, a signal indicative ofan error code.
 17. The system of claim 16, further comprising a remotedevice adapted and configured for wireless communication with thewireless controller, wherein the remote device is adapted and configuredto wirelessly receive an error code.
 18. The system of claim 17, whereinthe remote device is adapted and configured to display, on a display, amessage indicative of the type of error corresponding to the receivederror code.
 19. The system of claim 18, wherein the remote device is acell phone.
 20. The system of claim 18, wherein the remote device is atablet device.
 21. A method for wirelessly monitoring an electricgrill's status, comprising the steps of: using a microprocessor incommunication with a ground fault detection unit and a Hall Effectsensor to detect an error in the electric grill's operation; andtransmitting, wirelessly, an error code indicative of the error to aremote device.
 22. The method of claim 21, further comprising the stepsof: using the microprocessor to communicate with a thermocouple tomeasure the electric grill's temperature; using the microprocessor todetermine the electric grill's active time; transmitting, wirelessly,the electric grill's temperature and active time to the remote device.23. The method of claim 22, further comprising the steps of: using theremote device to display, at the remote device, a message indicative ofthe error received.
 24. The method of claim 23, further comprising thesteps of: using the remote device to create and store a log in a memory,wherein the log comprises an error code, the electric grill'stemperature, and the electric grill's active time.
 25. The method ofclaim 24, further comprising the step of using the remote device tocommunicate the log over the internet.
 26. The method of claim 22,further comprising the step of displaying, on a display at the electricgrill, the electric grill's temperature.
 27. The method of claim 26,further comprising the step of using the remote device to wirelesslytoggle the display between Celsius and Fahrenheit.
 28. The system ofclaim 1, wherein the microprocessor is a chip having a self-check pin,and the wireless controller is adapter and configured to wirelessly sendan erode code to the remote device in response to a self-check signalindicating a microprocessor error.